Automatic Engine Control Unit Operators Manual
Contents
1. the internal Heater Supply v 2 5 Amp rated Used to control external alarm buzzer Supply v 2 5 Amp rated Emergency Stop Input Connect to external emergency stop switch Oil Pressure Input Connect to Oil pressure sender 22 Auxiliary signal Output Energize to start Supply v 2 5 Amp rated 25 26 Coolant Temperature Input Connect to Coolant Temperature sender Overload sender Input Overload sender Input Connect to Overload sender 28 29 Low fuel sender Input Connectto fuel sender 30 AuxiliaryInput1 This is a negative switched configurable input 31 AuxiliaryInput2 This is a negative switched configurable input 32 Auxiliary Input3 This is a negative switched configurable input 33 AuxiliaryInput4 This is a negative switched configurable input Magnetic Pick Up Input v Connect to Magnetic Pick Up device AC signal from the magnetic pickup for speed sensing Magnetic Pick Up Input v Connect to Magnetic Pick Up device AC signal from the magnetic pickup for speed sensing ECU 02 Automatic Engine Control Unit Operators Manual 6 2 Specification 15V 380 ph ph 3 Phase 3wire AC 15 10 000 Hz max at rated engine speed CT Secondary Aid 7 FAULT FINDING SYMPTOM POSSIBLE REMEDY ECU 02 is inoperative Check if the emergency stop is push on Check the battery and wiring to the unit Check Battery Volts on cranking not below 6V Check the DC fuse F5 and F62. 02 Automatic Engine Control Unit Operators Manual 3 8 User Defined Inputs Alarm 1 To 4 The ECU 02 provides four alarm inputs which can be defined by the user for any function These alarms may be defined to provide warnings or shut downs to the engine Sensors can be closed or open signals as defined by the user To set the alarms see programming table 3 16 lines 34 to line 42 All four alarms sensors are the same except for Alarm 1 This first alarm provides the user a time delay function You can set the delay response time on alarm 1 from 0 to 99 Seconds using programming line 36 Alarms 2 3 and 4 respond immediately with no delay 3 9 Information On The Service Interval Display The engine service reminder is programmed into line 43 and can be set to 0 to 990 hours hours To program the hours between services press the PROM button and go to line 43 Using the DOWN UP buttons select the number of hours desired Each integer represents ten hours For example setting the number 2 will program a reminder of twenty hours Setting the number 40 will program a service interval of 400 hours If the HOUR LED starts flashing this is your reminder to give service to the generator set and afterwards reset the service meter Setting the hour to 0 will not provide a maintenance reminder To reset the service meter set the LED to HOUR by pressing the DOWN UP keys on the front display Next push the PR
3. 12 NOTE If the Remote Start signal is removed during the Pre heat Delay the unit will return to a stand by state after the Stop period After the above start delays the Fuel Solenoid and Starter Motor are energized The display will indicate St XX and the Starter cranking timer will count down on the front display panel The engine cranks for a pre programmed time period Should the engine fail to start during these first cranking attempts the starter motor disengages and the engine goes into pre heat again Should this sequence go beyond the set number of start attempts starting will be terminated and the start fault alarm will be displayed by a flashing AL 00 on the front panel After the engine starts the starter motor is automatically disengaged by sensing 1 or as may as 3 different signals from the engine These signals are 1 a pre set frequency 20 of rated frequency 2 output voltage from the generator and 3 oil pressure switch signal from the engine and or the signal from the Magnetic Pick Up Any one or up to all three signals can be use to disengage the starter motor NOTE If you program the oil pressure switch to disconnect the starter you may get a false oil pressure reading giving you premature starter disconnect and tricking the ECU to believe the engine is running For example when testing the engine with repeated starts when the engine is cool an
4. Check that operating temperature is not above 55 C Engine locks out on Emergency If the Emergency Stop Button is not used program line 24 to NO 0 Stop Check emergency stop switch is functioning correctly Check Wiring is not open circuit Check line 24 setting is correct Intermittent Magnetic Pick up Check magnetic pick up is functioning correctly sensor engine shutdown Check Wiring is not open circuit Check output voltage is not below less de 8 Volts RMS Low Oil Pressure shutdown after Check engine oil pressure engine has started Check oil pressure switch sender and wiring Check configured polarity is correct i e NO or NC High engine temperature shutdown Check engine temperature after engine has started Check switch sender and wiring Check configured polarity is correct i e NO or NC Check switch and wiring of fault indicated on display Check configuration of input Check relevant switch and wiring of fault indicated on display Check configuration of input Engine fail to Start despite Check fuel pre set number of attempts Check wiring of fuel solenoid Check battery supply Check the speed sensing signal is present on the inputs when in AUTO Check if engine Start Delay timer has timed out of Remote Start signal If remote start faults check if signal is on Remote Start input Check that pre heat has been selected in your program Check starter motor You have a 30 Amp limit Engine runs but generat
5. GOS en Automatic Engine Control Unit Operators Manual BURELL I RAROS KUTAI ELECTRONICS INDUSTRY CO LTD Headquarters No 3 Lane 201 Chien Fu ST Chyan Jenn Dist Kaohsiung TAIWAN Tel 886 7 8121771 Fax 886 7 8121775 URL http www kutai com tw ECU 02 ves Automatic Engine Control Unit Operators Manual BURELL RAROS 5 KUTAI ELECTRONICS INDUSTRY CO LTD 90 Headquarters No 3 Lane 201 Chien Fu ST Chyan Jenn Dist Kaohsiung TAIWAN Tel 886 7 8121771 Fax 886 7 8121775 URL http www kutai com tw ECU 02 Automatic Engine Control Unit Operators Manual TABLE OF CONTENTS Section Page INTRODUCTION ccs 5 tttm eh thine i ieee E 3 1 FRONT PANEL LAYOUT oae Hte Pe ee aed EE a Ee es 3 NW Front Panel Eayo t nete he ane eee 3 1 2 Rear Panel Layout a RL ale 3 2 OPERATION iius hRUtiiubnbdututeeuk iei ent iE Iit rte 4 gern PEEL 4 2 2 Auto Oe 4 2 3 Manual Mode Of Operation 5 2 4 Off Mode Of Operation 6 3 PROGRAMMING INSTRUCTIONS sse entere nennen snnt innert ensis nennen 6 Sel Battery Voltage mies e deua ES 6 EM tee LE Tu uN ET 6 3 3 Programming The Hour Meter misie eere a T A E EE E E A 7 3 4 Setting Up The Magnetic Pick Up en nennen sinn sn nennen 7 3 5 Volts And Amps Readout Programming sese eene ener nens 7 3 6 Notice For The ECU 02 Is Working Over 400 Volts Line 3 7 3 7 Generator Overload Protect Func
6. MS TINI MOT HOLFINOI C OT LVLS FLOW GIONA IOS TINA YOLON YAIYWIS JYVIS lt lt OL 4ojopjuoo dn wsom of dW M mdjno sampay of mdmo 4214v15 g mdmo dois oi oziBaaug AMALLVH IOIVHSNSA __ 21 a Transformer Unit PTU 03 ECU Voltage Isolation ACRAS RARD o KUTAI ELECTRONICS INDUSTRY CO LTD Headquarters No 3 Lane 201 Chien Fu ST Chyan Jenn Dist Kaohsiung TAIWAN Tel 886 7 8121771 Fax 886 7 8121775 URL http www kutai com tw Transformer Unit PTU 03 03 OPTION PTU TRANSFORMER UNIT TRANSFORMER UNIT PTU 03 F1 Fe LFS 12 3 Working with 208 240 volts generator PS Set the programming line 38 to 0 ECU 01 PTU 03 PIN7 TB1 3 Je r 741 PIN3 TB1 1 Status Rated Max Volt Ratio Input 600VAC Output Working with 380 480 volts generator PS Set the programming line 38 to 1 ECU 01 PTU 03 Output Output PIN7 TB1 3 s mec L1 PIN3 TB1 1 PIN5 TB1 2 12 GENERATOR PINS TB1 2 L2 GE
7. NERATOR 23
8. OM button on back panel for 1 second The ECU 02 is now reset and ready to remind you of your next engine service 3 10 Display Mode Setting The ECU 02 provides two display modes The user has the option to view the entire system s operating parameters Voltage Amps Frequency Hour meter and DC Voltage scrolled on the front display or one parameter at a time Programming line 44 to 1 allows you to view the voltage amps and frequency parameters for each phase in rotation automatically Each parameter will show on the front display for 2 sec and change to the next In this mode the ECU 02 allows you to STOP the scrolling to view specific parameter for 30 seconds by pressing the DOWN or UP buttons The ECU returns to automated scrolling after 30 seconds Programming line 44 to O allows you to view the specific parameters without scrolling You can change the display by simply pressing the DOWN UP buttons 3 11 Engine Test And Setup For Start Stop Led Lamp Test When testing and or setting up your engine with the ECU 02 for the first time you can override any engine STOP Commands thus enabling you to set up engine parameters without the engine stopping every time and interrupting your work This tool is very helpful when troubleshooting or when adjusting voltages and engine governors on a new engine Remember it is very important to preprogram line 24 correctly for Energize to STOP or Energize to START
9. P the fuel solenoid Is the STOP fuel Solenoid Energize to STOP or Energize to 0 gt Energize to STOP START 1 gt Energize to START t 23 R N Mi Mi n Ari o gt Co ECU 02 Automatic Engine Control Unit Operators Manual DESCRIPTION SETTING 25 Time for engine cool down without load 0 60 min 26 If a load contactor is used time allowed for engine warm up 0 99 sec before connecting the LOAD Temperature switch 0 gt NO Normally Open NO or normally closed NC NC Time before Generator STOPs if there is a problem with 0 60 sec engine temperature 0 No alarms 29 Enable or disable the alarm output pin 24 0 gt Disable 1 gt Enable Emergency STOP button gt N 1 gt NC Normally Open NO or normally closed NC X S E Ni m S 7 8 2 Overload sensor gt N 1 gt N Normally Open NO or normally closed NC x x i Low fuel sensor 0 gt NO 12 NC Normally Open NO or normally closed NC 34 Alarm1 Normally Open NO or normally closed NC 0 gt NO 1 NC 41 Alarm4 Normally Open NO or normally closed NC 0 gt NO 12 NC 42 Alarm 4 input 0 gt Warning 1 gt Stop Engine service interval reminder Refer to chapter 3 9 0 99 0 990H 0 No maintenance 44 Display mode setting Refer to chapter 3 10 0 gt Fix 1 gt Rotation Is the generator working in TOOL mode 0 NO say Normal Warning No Safety shutdowns on TOOL Mode 1 gt YES Tool Mode Al
10. Relay Module is the interface between the Pre heat start fuel stop and alarm output are automatic engine control module ECU 02 and the Pre assembled on the relay module Simply connect generator The ECU 11 amp ECU 22 provides two 18 the control wires to the correct terminals on the ways plugs to connect to ECU 02 module All the module thus minimizing assembly time and protected fuses and power relays for engine potential for errors when assembling and installing the engine control wires 2 ECU 11 12V amp ECU 22 24V Connection Details c A d E E a D m LA zi E D o Mm PF MD mm EN a mm WM KF A UA Mm D 1 i I D I li I li li 1 I 3 3 B a s iss e G 8 aale ei ieu KERLE G0O0O040 eeeeeeeeeeeccecoecoG DO LDE N 1 LADY TE De Ad AG PO e e e e e e e e e e e e e e e e e e e 99 99 e e e e e 99 e e e e 06 J1 E US PUR er E P M 388805888889888986 PUREE RP M HEN RE e elel e e El o e el e HH 1 The plug J1 Pin1 Pin18 connected to the plug J1 of ECU 02 2 The plug J2 Pin19 Pin36 connected to the plug J2 of ECU 02 2 1 Terminal TB2 Power And 30 Amp Output Connections DESCRIPTION DC Plant Supply Input v System DC negative input Battery Negative AWG10 DC Plant Supply Input v System DC positive input Battery Positive AWG10 Fuel sol
11. alarm conditions for which the triggering criteria have been removed If the engine is running and this position is selected the module will automatically shut down the generator The fuel supply will be removed and engine will be brought to a standstill Should a remote start signal be present while operating in this mode a remote start will not occur 3 PROGRAMMING INSTRUCTIONS NOTE Further programming and_ configuration must be made with the ECU 02 installed and connected to the battery 3 1 Battery Voltage The ECU 02 engine control unit automatically adjusts itself to DC12 or DC24 volts systems When cranking voltages drop sometimes to levels under 6Vdc that may render the ECU ineffective due to a low or defective battery Install new batteries or fix the starter If the unit freezes because of low cranking voltage it may be reset by disconnecting B from the battery for 4 seconds or you can simply push the reset button behind the front panel with a thin isolation tool for 1 second See 1 1 for front panel layout 3 2 Programming With the Selector Switch on OFF push the button PROM on the rear panel of ECU 02 for 4 seconds The word Ver 2 1 will appear on the front display for 2 seconds This number indicates the version of the software After that the word Pro will appear on the front panel for 4 seconds You are now ready to start a line by line programming seque
12. ctor Switch to OFF position to RESET After fixing the fault indicated See Table 4 4 below restart the generator and resume normal operation AL 10 AL 11 AL 12 AL 13 Low Battery Voltage SYMBOL DISCRIPTION LEVEL AL 00 AL 01 Over Speed Shut Down AL 02 Magnetic Pick Up Defective Shut Down AL 03 Wrong Voltage Shut Down AL 04 Low Engine Oil Pressure Shut Down AL 05 Emergency STOP Pushed Shut Down AL 06 High Engine Temperature Shut Down AL 07 Generator Over Loaded Shut Down AL 08 Shut Down or Warning AL 09 Option Shut Down or Warning Option2 shutDownor Warning Option3 shutDownor Warning Option 4 Shut Down or Warning Warning ECU 02 Automatic Engine Control Unit Operators Manual 5 INSTALLATION INSTRUCTIONS The model ECU 02 Module has been designed for front panel mounting Affixing the ECU 02 to the front panel is accomplished by 2 spring loaded clips located on each side of the module In conditions of excessive vibration the module should be mounted on suitable anti vibration mountings 5 2 Panel Cut Out All Dimensions In mm 5 1 Cooling The module has been designed to operate over a wide temperature range from 25 to 55 C Nevertheless allowances should be made for temperature increases within the control panel enclosure Care should be taken NOT to mount possible heat sources near the module i e battery charg
13. d the crankcase oil is thick and certain types of engines that build UP oil pressure quickly before engine start If this is the case remember that you have other programmable choices for disengaging the starter that are equally as effective After the starter disengages and the engine is running normally a grace period is activated This grace period allows oil pressure engine speed voltage and any other delayed Auxiliary inputs to be stabilized before monitoring and triggering any faults if any After the engine is running the Engine Warm UP timer if selected is initiated The Warm UP timer allows the engine to warm up and stabilize before accepting any loads A signal is given to a load transfer contactor to activate and take up the load BE AWARE that some generators sets have no Load Contactor ECU 02 Automatic Engine Control Unit Operators Manual NOTE A load transfer output will not be initiated until the Oil Pressure Engine Speed and alternating voltages have risen and are all normal With the return of normal power the ATS removes the Remote Start signal The load transfer contactor is the first to be de energized removing the load and initiating the engine Cool Down phase engine with no load The display will indicate CL XX and the Cool Down delay timer will count down on the front display panel Please be aware if your ATS also includes the abo
14. e for use with Electronic Governors Battery charging alternator exciter Etc Alarm signal Output For use with an external alarm Supply v 5 Amp rated Emergency Stop Input Connect to external emergency stop switch Panic Button Oil Pressure Input Connect to Oil pressure sender Coolant Temperature Input Connect to Coolant Temperature sender Overload sender Input Connect to Overload sender Low fuel sender Input Connect to low fuel indicator switch sensor Auxiliary Input 1 This is a negative switched configurable input with time out Auxiliary Input 2 This is a negative switched configurable input Auxiliary Input 3 This is a negative switched configurable input Auxiliary Input 4 This is a negative switched configurable input Not Used Spare Magnetic Pick up Input v Connect to Magnetic Pickup device AC signal from the magnetic pick up for speed sensing Magnetic Pick up Input v Connect to Magnetic Pickup device AC signal from the magnetic pick up for speed sensing ECU 11 12V amp ECU 22 24V Relay Module 3 ECU 11 12V amp ECU 22 24V Typical Wiring Diagram ECU 02 Connect Wire Diagram With ECU 11 or ECU 22 Relay Board BERRERBRERE E 22 08 U MA Bz rep Cen Det TLONTY eNMVTV ENWVTIV FNUVTV JIVAH Hd
15. e you start the generator 5 is automatically added reading 205 volts on the ECU To achieve the same synchronization for amperage AMPS program line 7 to desired level ECU 02 Automatic Engine Control Unit Operators Manual 3 6 Notice For The Ecu 02 Is Working Over 400 Volts Line 3 It is dangerous to feed high voltage to the ECU Printed Circuit boards The highest input voltage the ECU 02 can safely read is 400 volts To work at over 400 volts we have developed two clear simple methods 1 One approach is to use the 1 to transformer provided Part NO PTU 03 Feed 480 volts into the transformer input and connect the ECU to 1 2 voltage transformer output Then set programming line 3 to 1 Now the ECU 02 automatically doubles the input voltage on the display Working with 380 to 480 volts Generator T2 PIN7 PIN3 PINS Setting line 3 to yes 1 Read out volt input volts 2 ECU 02 2 Another method is to connect the voltage sensing wires to the first Star using lines T7 T8 amp T9 on the generator See diagram 3 6 below Next set programming line 3 to 1 The ECU 02 automatically doubles the input voltage on the display Using this method the Isolating transformers remain 1 to 1 Working with 208 to 240 volts Generator T2 L2 PIN7 PIN3 PINS Setting line 3 to no 0 Read out volt input volts 1 ECU 02 DIAGRAM 3 6 ECU 02 Automatic Engine Contro
16. enoid signal output Controls the fuel solenoid or engine fuel control system Programmable to ET STOP or Supply v 30 Amp rated ET START Start signal output Controls the Starter Motor Supply v 30 Amp rated Pre heat signal output Controls the engine pre heater Supply v 30 Amp rated ECU 11 12V amp ECU 22 24V Relay Module 2 2 Terminal TB3 DESCRIPTION Generator L3 sensing input Connect to alternator L3 output Not Used Spare Generator L2 sensing input Connect to alternator L2 output Not Used Spare Generator L1 sensing input Connect to alternator L1 output Not Used Spare Warm up signal Output Used to control the Warm up contactor 5 Amp rated Warm up signal Output Used to control the Warm up contactor 5 Amp rated CT secondary for L3 Connect to secondary of L3 monitoring CT CT secondary for L3 Connect to secondary of L3 monitoring CT CT secondary for L2 Connect to secondary of L2 monitoring CT CT secondary for L2 Connect to secondary of L2 monitoring CT CT secondary for L1 Connect to secondary of L1 monitoring CT CT secondary for L1 Connect to secondary of L1 monitoring CT Remote start input Connect to A T S remote start contact Remote start input Connect to A T S remote start contact Auxiliary signal Output Energize to start v 5 Amp rated Not Programmabl
17. ers unless adequate ventilation is provided The relative humidity inside the control panel enclosure should not exceed 85 5 3 Unit Dimensions All Dimensions In mm 14 ECU 02 Automatic Engine Control Unit Operators Manual 6 ELECTRICAL CONNECTIONS 6 1 Connection Details On The ECU 02 PLUG J1 18 WAY DESCRIPTION NotUsed O Net User Generator L3 sensing input Connect to alternator L3 output NotUsed Generator L2 sensing input Connect to alternator L2 output NotUsd Generator L1 sensing input NotUsed CT secondary for L3 CT secondary for L3 Connect to secondary of L3 monitoring CT CT secondary for L2 Connect to secondary of L2 monitoring CT Connect to alternator L1 output Connect to secondary of L3 monitoring CT Connect to secondary of L2 monitoring CT Connect to secondary of L1 monitoring CT Connect to secondary of L1 monitoring CT Connect to A T S device Connect to A T S device System DC negative input Battery Negative DC Plant Supply Input v System DC positive input Battery Positive Recommended fuse 2 Amp DESCRIPTION NOTES Used to control the Warm UP contactor Supply v 2 5 Amp rated Used to control the fuel solenoid or engine fuel control system Supply v 2 5 Amp rated Used to control the Starter Motor Supply v 2 5 Amp rated Used to control
18. for your engine type before using this handy tool Programming line 45 to 1 allows you to manual start and stop the engine by pressing the key to start and key to STOP When you are using this tool all the LED s on the panel are lit so that you may also test all the LED lamps When finished utilizing the Engine override function push the PROM button one time and the word END will appear on the front display The ECU 02 will return Line 45 to 0 automatically 10 ECU 02 Automatic Engine Control Unit Operators Manual 3 12 Line By Line Programming Table FACTORY DESCRIPTION SETTING SETTING Is this generator operating in 3 phase or 1 phase 0 gt 3 Phase 1 gt 1 Phase Fine calibration of Voltage read out Refer to chapter 3 5 50V 50V If the ECU is going to work over 400 volt 0 gt No 1 gt Yes If Yes go to chapter 3 6 and read related information 0 volt 1 1 volt 2 Set Under Voltage by setting a number from 16 to 47 10 18 16 47 160 470 V For example the number 18 represent 180 volts etc 180V 47 160 Set Over Voltage by setting a number from 23 to 55 10 25 23 55 230 550 V For example the number 25 represent 250 volts etc 250V N Time before Generator STOPs if there is a problem with the 0 60 sec generator voltage output 0 No alarms 7 Calibrate the AMPS read out Refer to chapter 3 5 50A 50A Tell ECU 02 what CT C
19. l Unit Operators Manual 3 7 Generator Overload Protection Function The function of the Generator overload protector is to STOP the engine if it is overworked by the customer or if the engine goes over a given Amps set point established by the generator Current Transformer Connection operator This setting is easily changed and it has adequate delays to compensate for temporary normal overloads Correct and ONLY schema for CT connection REMOTE START REMOTE START if CH 1040 COARATINR e e bem P li Remate start DIAGRAM 3 7 NOTE Wire each CT individually into the ECU 02 Do not Daisy Chain or Ground any CT See Diagram 3 7 When the ECU 02 detects a overload above the set point and this overload continues over the delay time set by line 10 the ECU 02 will shutdown the engine and show AL 07 alarm on the front panel To reprogram a cut off point go to line 9 and select a power unit needed Programming 1 power unit into line 9 is equal to 50 Amps of load 1 power unit 50 amps For example programming line 9 with 20 units represents an overload cut off current of 1000 Amps 50 20 1000 NOTE Never set line 9 to a value larger then the CT current transformer correctly inside the generator For example if we are using 1000 5A CTs line 9 can not be programmed to a value larger 20 x 50 1000amps etc ECU
20. mance and gives the operator digital readouts for all working parameters The module will by design stop the engine and diagnose engine generator failures on a large easy to read 4 digit 7 segment front display panel with flashing light emitting diodes LED s Remote starting is accomplished via standard two wire 1 FRONT PANEL LAYOUT 1 1 Front Panel Layout RESET 1 2 Rear Panel Layout signals from any Automatic Transfer Switch or remote switch Model ECU 02 also includes a generator overload protection The module also features easily adjustable operational sequences timers and alarm trips These customizations can be programmed easily by the customer via the rear and front display panel These are the buttons PROM on rear and on the front There is no need for a PC connection and programming software Any and all changes can be made in the field Auto Manual Genset Controller KEY SWITCH KUTAI ELECTRONICS INDUSTRY CO LTD URL http www kutai com tw ECU 02 Automatic Engine Control Unit Operators Manual 2 OPERATION 2 1 Control The ECU 02 is controlled by using the front display panel Selector Switch See 1 1 There are only three positions from which to choose AUTO OFF and MANUAL The Selector Switch is the only control you need to operate the generator The Selector Switch is framed by two small push buttons DOWN UP See 1 1 These buttons access more comple
21. nce To advance to the next line push the PROM button on the back panel See 1 2 Use the UP and DOWN buttons to change each line s programming parameters ECU 02 Automatic Engine Control Unit Operators Manual Always push the PROM button to advance to next programming line or until the word END appears on the screen To immediately end the programming mode you can simply push the PROM button for 4 seconds at any time The word END on the front display panel indicates a return to previous settings Should you make an error or desire to return to factory settings stay in Pro mode and simultaneously press all 3 buttons UP DOWN and PROM for 4 seconds The ECU 02 will now automatically program itself to factory settings and the word Au Po will appear on the display See table 3 12 for ECU 02 factory settings 3 3 Programming The Hour Meter Turn the Selector Switch to the OFF position Push the PROM button on the rear panel until the word Pro appears on the screen Push the UP key one time quickly before the word Pro disappears The front display will read Ch Hr indicating the operating hours of the gen set To reconcile the ECU 02 with the gen set s hours For example to set the ECU 02 at 200 hours to match a gen set with 200 previous operating hours push the UP and DOWN buttons to the number of hours desired After re
22. or will not Check if warm up timer has timed out take load Check warm up has been selected in your configuration 16 ECU 02 Automatic Engine Control Unit Operators Manual 8 TYPICAL WIRING DIAGRAM 139 N35 Kg Emergency Stop Low Oil Pressure High Temperature Overload Sensor Low Fuel Sensor P Alarm 1 vet Alarm 2 Alarm 3 Alarm 4 Meganetic 5 Pick up H 5 w go go o go go ish m Es E o ct o o s o E o 5 O D o D Q D Q9 lt E P D 3 Remote Start From ATS Panel H AYALLVd amp o Stop Starter 4 amp V Auxiliary Jo oe1uo9 df w em Pre Heat rch Alarm 4 17 ECU 11 12V amp ECUL22 24V Relay Module And Harness For Quick Installation of ECU slr ee Du ERIS o KUTAI ELECTRONICS Co LTD Headquarters No 3 Lane 201 Chien Fu ST Chyan Jenn Dist Kaohsiung TAIWAN Tel 886 7 8121771 Fax 886 7 8121775 URL http www kutai com tw ECU 11 12V amp ECU 22 24V Relay Module ECU 11 12V amp ECU 22 24V RELAY MODULE OPERATORS MANUAL 1 Introduction The
23. setting the hour meter simply push the PROM button again The word END on the panel indicates that you are back to normal operating mode 3 4 Setting Up The Magnetic Pick Up Prior to setting the magnetic Pick Up Refer table 3 12 you must program lines 12 13 14 15 and 19 Then start the engine and run it at normal speed 50 or 60 Hz Next set the LED on the front display panel next to FREQ using the UP and DOWN buttons When 50 or 60Hz appears on the LED push the PROM button for one second and Pro will appear If FAIL appears check the MPU wires and installation and try again The ECU 02 is now programmed with an over speed trip using the Magnetic Pick Up that is dependent on the settings for line 14 10596 11096 11596 or 12096 above rating speed plus a 2096 automatic starter motor disconnect If any wires on the Magnetic Pick Up break the ECU 02 automatically shuts down the engine and shows the flashing alarm signal AL 02 on the front screen 3 5 Volts And Amps Readout Programming Programming lines 2 amp 7 are used for fine calibration of the VOLTS amp AMPS readout This option is used only if you have a calibrated service meter that you want to synchronize with the readings from the ECU 02 For example If the ECU reads 200 Volts but your Calibrated Mete reads 205 volts you can easily add 5 volts to the ECU readout by putting the number 5 on line 2 The next tim
24. so LED Lamp Test Refer to chapter 3 11 gt o gt ER z XJ Ox EI 33 94 Ei 36 37 EI EI 40 EN 42 12 ECU 02 Automatic Engine Control Unit Operators Manual 4 PROTECTIONS AND ALARMS 4 1 Information On The Display The ECU 02 has a 4 digit display easily visible digital display The 4 digit display indicates e Generator output voltage on each phase with the buttons Generator output current on each phase with the buttons Frequency Total running hour Service Battery voltage Programming parameter Fault alarms Timer count downs Using with the Up DOWN buttons you may select VOLT AMP FREQ HOUR and Battery Voltage on the front display screen To observe individual Voltage and Amperage on each phase press UP button On a single phase system the UP key has no function 4 4 Alarms Table NOTE Set system phase seiting in line 1 correctly If set incorrectly the ECU 02 will read the wrong voltage values 4 2 Alarms Alarms are non critical warning conditions and do not affect the operation of the generator system They serve to draw the operator s attention to an undesirable condition The warning alarm will reset automatically after the problem is fixed 4 3 Engine Stop Shutdowns Engine STOPS SHUTDOWNS are latching or final To restart the engine the alarm must be accepted and cleared Turn the Sele
25. tion sese eene nennen nnne en 8 3 8 User Defined Inputs Alarm 1 To Arerian aaa aa Ra SER ara EAEra Na rE AaS S 8 3 9 Information On The Service Interval Display 9 3 10 Display Mode Setting EE 9 3 11 Engine Test And Setup For Start Stop Led Lamp Test 10 3 12 Line By Line Programming Table 10 4 PROTECTIONS AND ALARMS oe ER ee eed ni 12 4 1 Information On The Display cccccceesceceeeeeceeeeeeaeseeneecaeeeeaaeeeeaaeseaeeecaaeeeeaaeseseeeeneeesaeeeeaaeesenees 12 LINE m 12 4 3 Engine Stop Gbutdowns estne enters ns intent innen inns nnns nn neni 12 4 4 Alarms Table Am 12 5 INSTALLATION INSTRUCTIONS entretenir intres en nennen sinerent 13 sinere ek Yh eee a aks ae ast ae a re ace i ee 13 5 2 Panel Cut Out All Dimensions In mm 1 13 5 3 Unit Dimensions All Dimensions In mm 1 13 6 ELECTRICAL CONNECTIONS sse entren nennen sinn sn tres en rennen sn nrnn senes 14 6 1 Connection Details On The ECU 02 viskes itarar iaia eare iadaa e nennen nia entere nsns nnns entren 14 62 Specificato Nse EE 15 Ta FEAUETFINDING neni et tetro dotem freien ts 15 8 TYPICAL WIRING DIAGRAM IF ECU RELAY BOARD IS NOT USED sene 16 ECU 02 Automatic Engine Control Unit Operators Manual INTRODUCTION The ECU 02 Generator Control module is used to start and stop a generator set automatically In addition to its automatic start stop function the module monitors any problems related to engine generator perfor
26. urrent Transformer is going to be 1 255 2505 3 60 5 installed 43755 521005 62 150 5 7 gt 200 5 8 250 5 9 300 5 10 gt 400 5 11 gt 500 5 12 gt 600 5 For example if installing a 100 5A CT program the number 5 13 gt 750 5 14 800 5 15 1000 5 into ECU 02 etc 16 gt 1200 5 17 gt 1500 5 18 gt 1600 5 19 gt 2000 5 20 gt 3000 5 Overload setting Refer to chapter 3 7 1 60 50 3000A 2 100A Time before Generator STOPs if there is a problem with the 0 99 sec generator overload 0 No alarms 1 At what frequency Hertz will generator operate 0 60 Hz 1 gt 50 Hz 2 Test for Over speed 0 gt No 1 gt Yes Test Over speed using the generator output or Magnetic 0 gt Generator Pick Up 1 gt Magnetic Pick Up Over speed shutdown setting 1 gt 105 2 gt 110 3 gt 115 4 gt 120 Time before Generator STOPs if there is a problem with 0 60 sec generator frequency output 16 Time to set Pre Heat of engine 0 30 sec 0 No Pre Heat ITEM 2 ER 17 Number of start attempts 18 Time to run the engine starter with each engine start 19 Remove starter by using the Magnetic Pick up 20 Remove starter by using engine oil pressure sensor Low oil pressure switch 0 gt NO 12 NC Normally Open NO or normally close NC am aw Time before Generator STOPs if there is a problem with low 0 60 sec oil pressure 0 No alarms Time to Energize to STO
27. ve mentioned sequences If so then your timed sequences will run concurrently combining the time programmed For example if you have a sixty second cool down on an ATS and sixty second cool down programmed on the ECU 02 your total cool down will be 120 seconds To avoid this redundancy set the ECU 02 timing delays i e warm up cool down to 0 if your ATS includes these functions After the Cool Down times out the Fuel Solenoid is de energized or energized as the case may be bringing the generator to a stop The front display will indicate SP XX and the Stop delay timer will count down on the front panel The ECU will reset and the remote start LED will start flashing indicating the generator is on standby and ready to start Should the Remote start signal be re activated during the cooling down period the set will immediately return to load 2 3 Manual Mode Of Operation Manual operation is conducted by turning the Selector Switch to Manual on the front display panel See 1 1 The start sequence is the same as in the AUTO MODE sequence of operation See 2 2 above Turning the Selector Switch to OFF stops the engine after cool down In Manual the MANU LED is illuminated NOTE In manual mode of operation the ATS will not operate the ECU 02 Remote start is disabled 2 4 Off Mode Of Operation The OFF position places the module into its Stop or Reset mode This will clear any
28. x information such as Voltage VOLT and Amperage AMP on each phase L1 2 L2 3 L3 1 FREQ in Hertz HOUR hour meter BATT battery voltage and remaining time until next service These functions are described in greater detail in section 3 9 3 11 2 2 Auto Mode Of Operation With the Selector Switch on the Automatic position the ECU 02 controls all the functions of the generator set The two Remote Start Inputs see 1 2 terminals 15 and 16 on the ECU 02 are monitored constantly Once the start condition is signaled by an Automatic Transfer Switch or a remote start switch the ECU 02 commences the start sequence The generator automatically is then placed on load AUTO SEQUENCE The flashing AUTO LED on the front panel see 1 1 indicates at a glance that the generator set is on stand by and ready to start When a Remote Start signal is given by the ATS the AUTO LED stops flashing indicating that the engine is on start countdown and will start If the engine needs Pre heat and this option is selected the ECU 02 starts pre heating the engine and the corresponding relay output is energized The front display will read Ph XX and the Pre heat timer will count down the seconds on the front panel Setting 0 NO Pre heat on the programming sequence will set an automatic 5 second engine start delay before starting the engine The display will indicate 05 For additional instruction on programming See 3
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